Komatsu D135A-2 Dozer Bulldozer Shop Manual SEBM015A0205 PDF
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Komatsu D135A-2 Dozer Bulldozer Shop Manual SEBM015A0205 – PDF DOWNLOAD
- MACHINE MODEL SERIAL No.
D135A-2 10301 and up
Description
Komatsu D135A-2 Dozer Bulldozer Shop Manual SEBM015A0205 – PDF DOWNLOAD
FILE DETAILS:
Komatsu D135A-2 Dozer Bulldozer Shop Manual SEBM015A0205 – PDF DOWNLOAD
Language : English
Pages : 479
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu D135A-2 Dozer Bulldozer Shop Manual SEBM015A0205 – PDF DOWNLOAD
- MACHINE MODEL SERIAL No.
D135A-2 10301 and up
COVER . 1
CONTENTS 2
10 STRUCTURE AND FUNCTION . 23
GENERAL . 24
POWER TRAIN HYDRAULIC SYSTEM 26
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM . 27
TORQUE CONVERTER 28
TORQFLOW TRANSMISSION . 32
TRANSMISSION CONTROL 38
TORQFLOW HYDRAULIC PIPING . 39
TORQFLOW HYDRAULIC SYSTEM . 40
TORQFLOW HYDRAULIC CIRCUIT DIAGRAM 41
TRANSMISSION CONTROL VALVE 42
TRANSMISSION LUBRICATION RELIEF VALVE . 47
TRANSMISSION PUMP . 48
TRANSMISSION AND STEERING OIL STRAINER 49
TRANSMISSION OIL FILTER . 50
BEVEL GEAR SHAFT AND STEERING CLUTCH 51
STEERING CONTROL 53
STEERING AND BRAKE PIPING . 54
STEERING AND BRAKE HYDRAULIC SYSTEM . 55
STEERING AND BRAKE HYDRAULIC CIRCUIT DIAGRAM 56
STEERING PUMP . 57
STEERING MAIN RELIEF VALVE 58
STEERING AND BRAKE CONTROL VALVE 59
STEERING BRAKE 63
SPRING ASSIST BRAKE SYSTEM 67
FINAL DRIVE . 71
PTO (POWER TAKE OFF) 72
TRACK FRAME . 73
IDLER CUSHION . 74
IDLER . 75
TRACK ROLLER AND CARRIER ROLLER . 76
TRACK (LUBRICATED TRACK LINK) . 77
TRACK (DRY TYPE TRACK LINK) . 78
SUSPENSION 79
HYDRAULIC PIPING 80
HYDRAULIC CONTROL . 82
HYDRAULIC SYSTEM (WITHOUT RIPPER) . 84
HYDRAULIC CIRCUIT DIAGRAM (WITHOUT RIPPER) 85
HYDRAULIC SYSTEM (WITH RIPPER) 86
HYDRAULIC CIRCUIT DIAGRAM (WITH RIPPER) . 87
HYDRAULIC TANK (WITHOUT RIPPER) . 88
HYDRAULIC TANK (WITH RIPPER) 89
HYDRAULIC PUMP 90
BLADE CONTROL VALVE . 91
MAIN RELIEF VALVE (WITHOUT RIPPER) 98
RIPPER CONTROL VALVE 99
HYDRAULIC LEVER OPERATION .104
HYDRAULIC CYLINDER 108
CYLINDER STAY .112
STRAIGHT TILTDOZER 113
VARIABLE MULTIPLE SHANK RIPPER 115
ELECTRICAL CIRCUIT DIAGRAM 117
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM) .119
AIR CONDITIONER .125
20 TESTING AND ADJUSTING 127
TABLE OF STANDARD VALUES FOR ENGINE .128
TABLE OF STANDARD VALUES FOR CHASSIS 129
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE 134
TESTING AND ADJUSTING .136
TESTING AND ADJUSTING TOOL LIST .137
ADJUSTING VALVE CLEARANCE .138
MEASURING COMPRESSION PRESSURE 139
TESTING AND ADJUSTING FUEL INJECTION TIMING .140
MEASURING TORQUE CONVERTER STALL SPEED 141
BLEEDING AIR FROM FUEL SYSTEM .142
BLEEDING AIR FROM HYDRAULIC CYLINDER 142
MEASURING OIL PRESSURE 143
ADJUSTING FUEL CONTROL LINKAGE 145
ADJUSTING GEAR SHIFT LEVER LINKAGE 147
ADJUSTING STEERING CLUTCH LINKAGE .149
ADJUSTING BRAKE PEDAL TRAVEL 150
ADJUSTING BRAKE PEDAL LINKAGE .151
ADJUSTING BRAKE CONTROL LINKAGE .153
ADJUSTING RIPPER CONTROL LINKAGE 154
ADJUSTING CLEARANCE OF IDLER 155
H-MODE TROUBLESHOOTING 157
PREPARATION FOR TROUBLESHOOTING .158
METHOD OF READING TROUBLESHOOTING TABLE .160
PREVENTING RECURRENCE OF THE SAME TROUBLE .162
TROUBLESHOOTING .163
H-1 TORQUE CONVERTER TEMPERATURE TOO HIGH .163
H-2 MACHINE DOES NOT MOVE .164
H-3 MACHINE LACKS POWER OR SPEED 166
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR .167
H-5 MACHINE MOVES WHEN ENGINE IS STARTED 168
H-6 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 168
H-7 MACHINE TRAVELS IN ONE DIRECTION ONLY (FORWARD OR REVERSE) 168
H-8 STEERING CLUTCH DOES NOT DISENGAGE 169
H-9 STEERING CLUTCH SLIPS .170
H-10 STEERING BRAKE DOES NOT WORK .171
H-11 BLADE LIFT LACKS POWER AND SPEED .172
H-12 BLADE DOES NOT LIFT 173
H-13 THE FRONT OF MACHINE CANNOT BE RAISED OFF GROUND BY THE BLADE 174
H-14 HYDRAULIC DRIFT OF LIFT CYLINDER IS LARGE 175
H-15 BLADE MOVES UNSTEADILY WHEN LEVELING THE GROUND (CONTROL LEVER IN “HOLD”) 176
H-16 BLADE LOWERS UNDER THE FOLLOWING CONDITIONS 176
H-17 TRAVEL OF THE PISTON RODS IN THE RIGHT AND LEFT LIFT CYLINDERS IS DIFFERENT(APPLICABLE TO STRAIGHT -TILT DOZER ONLY) .176
H-18 BLADE TILTING FORCE IS LACK, BLADE TILTING SPEED IS SLOW, THE MACHINE CANNOT BE RAISED OFF GROUND BY BLADE TILTING FORCE .177
H-19 TILT CYLINDER DOES NOT MOVE OFF (TILTING IS IMPOSSIBLE) 178
H-20 HYDRAULIC DRIFT OF TILT CYLINDER IS LARGE 179
H-21 HYDRAULIC DRIFT OF RIPPER CYLINDER IS LARGE 180
H-22 OPERATING FORCE IS HEAVY .181
M-MODE TROUBLESHOOTING 182
POSITION OF CONNECTORS FOR TROUBLESHOOTING 183
CONNECTOR TYPE AND MOUNTING POSITION 184
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 185
PROCEDURE FOR TROUBLESHOOTING .189
CHECKS BEFORE TROUBLESHOOTING .190
METHOD OF USING TROUBLESHOOTING CHART .191
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM) 193
M-1 NO MONITOR PANEL DISPLAY IS GIVEN WHEN STARTING SWITCH IS TURNED ON .194
M-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MONITOR PANEL STAY LIGHTED AND DO NOT GO OUT 194
M-3 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHECK ITEMS FLASH. (CHECK ITEM LEVELS ARE AT SPECIFIED LEVEL) 195
M-4 NO PREHEATING IS BEING CARRIED OUT, BUT PREHEATING DISPLAY LIGHTS UP 196
M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH 197
M-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CAUTION ITEMS FLASH 198
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH. (WHEN THERE IS AN ABNORMALITY IN THE ENGINE OR IN THE CHECK ITEMS.) 199
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR ONE SECOND 202
a) CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND .202
b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY,BUT BUZZER SOUNDS .202
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), LAMPS DO NOT LIGHT UP FOR 2 SECONDS .203
a) CAUTION ITEM IS FLASHING,BUT WARNING LAMPS DOES NOT FLASH 203
b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY,BUT LAMPS LIGHT UP 203
M-10 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP 204
M-11 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED 205
M-12 WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE .206
M-13 WATER TEMPERATURE GAUGE GIVES NO DISPLAY .206
M-14 TORQUE CONVERTER OIL TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE 207
M-15 TORQUE CONVERTER OIL TEMPERATURE GAUGE GIVES NO DISPLAY 207
M-16 FUEL GAUGE ALWAYS DISPLAYS TANK FULL .208
M-17 FUEL GAUGE GIVES NO DISPLAY 208
30 DISASSEMBLY AND ASSEMBLY .209
METHOD OF USING MANUAL 211
PRECAUTIONS WHEN CARRYING OUT OPERATION .212
SPECIAL TOOL LIST .214
WEIGHT TABLE 219
TABLE OF TIGHTENING TORQUE AND STANDARD VALUE .221
TABLE OF OIL AND COOLANT QUANTITIES .234
PRECAUTIONS WHEN HANDLING PIPING DURING DISASSEMBLY .235
STARTING MOTOR 237
REMOVAL .237
INSTALLATION 237
ALTERNATOR 237
REMOVAL .237
INSTALLATION 237
AIR COMPRESSOR 237
REMOVAL .237
INSTALLATION 237
NOZZLE HOLDER .239
REMOVAL .239
INSTALLATION 239
FUEL INJECTION PUMP .239
REMOVAL .239
INSTALLATION 239
ENGINE OIL COOLER .241
REMOVAL .241
INSTALLATION 241
THERMOSTAT 241
REMOVAL .241
INSTALLATION 241
WATER PUMP 241
REMOVAL .241
INSTALLATION 241
TURBOCHARGER 241
REMOVAL .241
INSTALLATION 241
CYLINDER HEAD .243
REMOVAL .243
INSTALLATION 247
RADIATOR GUARD 249
REMOVAL .249
INSTALLATION 249
RADIATOR 251
REMOVAL .251
INSTALLATION 251
PTO .251
REMOVAL .251
INSTALLATION 251
DISASSEMBLY .253
ASSEMBLY 255
FUEL TANK .257
REMOVAL .257
INSTALLATION 257
ENGINE 259
REMOVAL .259
INSTALLATION 263
TORQUE CONVERTER 265
REMOVAL .265
INSTALLATION 265
DISASSEMBLY .267
ASSEMBLY 273
TORQUE CONVERTER RELIEF VALVE .279
REMOVAL .279
INSTALLATION 279
DISASSEMBLY .279
ASSEMBLY 279
TORQUE CONVERTER REGULATOR VALVE 279
REMOVAL .279
INSTALLATION 279
DISASSEMBLY .279
ASSEMBLY 279
TRANSMISSION 281
REMOVAL .281
INSTALLATION 281
DISASSEMBLY .283
ASSEMBLY 295
TRANSMISSION CONTROL VALVE 309
REMOVAL .309
INSTALLATION 309
DISASSEMBLY .311
ASSEMBLY 313
TRANSMISSION LUBRICATION VALVE 315
REMOVAL .315
INSTALLATION 315
DISASSEMBLY .315
ASSEMBLY 315
BEVEL GEAR AND SHAFT 317
DISASSEMBLY .317
ASSEMBLY 319
STEERING CLUTCH .325
REMOVAL .325
INSTALLATION 325
DISASSEMBLY .327
ASSEMBLY 327
STEERING RELIEF VALVE .329
REMOVAL .329
INSTALLATION 329
DISASSEMBLY .329
ASSEMBLY 329
BRAKE BOOSTER .331
DISASSEMBLY .331
ASSEMBLY 331
STEERING AND BRAKE VALVE 331
REMOVAL .331
INSTALLATION 331
DISASSEMBLY .333
ASSEMBLY 333
TRANSMISSION PUMP .335
REMOVAL .335
INSTALLATION 335
STEERING PUMP .335
REMOVAL .335
INSTALLATION 335
ASSIST BRAKE CYLINDER .335
REMOVAL .335
INSTALLATION 335
DISASSEMBLY .337
ASSEMBLY 339
NO.1 PINION .343
DISASSEMBLY .343
ASSEMBLY 345
FINAL DRIVE .347
DISASSEMBLY .347
ASSEMBLY 351
TRACK FRAME .357
REMOVAL .357
INSTALLATION 357
RECOIL SPRING .359
REMOVAL .359
INSTALLATION 359
DISASSEMBLY .361
ASSEMBLY 361
IDLER .363
REMOVAL .363
INSTALLATION 363
TRACK ROLLER 363
REMOVAL .363
INSTALLATION 363
CARRIER ROLLER 365
REMOVAL .365
INSTALLATION 365
TRACK SHOE 365
REMOVAL .365
INSTALLATION 365
OVERALL DISASSEMBLY .367
OVERALL ASSEMBLY 372
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 388
FIELD DISASSEMBLY OF ONE LINK .389
FIELD ASSEMBLY OF ONE LINK 391
DISASSEMBLY OF MASTER LINK 393
ASSEMBLY OF MASTER LINK .395
HYDRAULIC PUMP 398
REMOVAL .398
INSTALLATION 398
BLADE CONTROL VALVE .398
REMOVAL .398
INSTALLATION 398
DISASSEMBLY .400
ASSEMBLY 402
RIPPER CONTROL VALVE 404
REMOVAL .404
INSTALLATION 404
DISASSEMBLY .404
ASSEMBLY 404
BLADE RELIEF VALVE 406
DISASSEMBLY .406
ASSEMBLY 406
RIPPER RELIEF VALVE .406
DISASSEMBLY .406
ASSEMBLY 406
BLADE LIFT CYLINDER .408
REMOVAL .408
INSTALLATION 408
BLADE TILT CYLINDER .408
REMOVAL .408
INSTALLATION 408
RIPPER LIFT CYLINDER 410
REMOVAL .410
INSTALLATION 410
RIPPER TILT CYLINDER 410
REMOVAL .410
INSTALLATION 410
HYDRAULIC CYLINDER 412
DISASSEMBLY .412
ASSEMBLY 416
BLADE .420
REMOVAL .420
INSTALLATION 420
DISASSEMBLY .422
ASSEMBLY 422
MULTIPLE SHANK RIPPER .424
DISASSEMBLY .424
ASSEMBLY 424
CAB .426
REMOVAL .426
INSTALLATION 426
TURNING OVER ROPS CAB .428
REMOVAL .428
INSTALLATION 430
40 MAINTENANCE STANDARD .432
TORQUE CONVERTER 433
TORQFLOW TRANSMISSION .435
TRANSMISSION CONTROL VALVE 437
TRANSMISSION LUBRICATION VALVE 439
TRANSMISSION PUMP .440
BEVEL GEAR SHAFT 441
STEERING CLUTCH .443
STEERING PUMP .445
STEERING MAIN RELIEF VALVE 446
STEERING AND BRAKE CONTROL VALVE 447
STEERING BRAKE .449
ASSIST BRAKE CYLINDER .451
ASSIST BRAKE AUTOMATIC DRAIN VALVE 452
FINAL DRIVE .453
TRACK FRAME .455
RECOIL SPRING .456
IDLER .457
TRACK ROLLER 459
CARRIER ROLLER 461
TRACK .462
SUSPENSION 466
HYDRAULIC PUMP 467
BLADE CONTROL VALVE .468
RIPPER CONTROL VALVE 470
HYDRAULIC CYLINDER 472
CYLINDER STAY .475
STRAIGHT TILTDOZER 476
VARIABLE MULTI-SHANK RIPPER .478
DESCRIPTION:
Komatsu D135A-2 Dozer Bulldozer Shop Manual SEBM015A0205 – PDF DOWNLOAD
- MACHINE MODEL SERIAL No.
D135A-2 10301 and up
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual care- fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
PREPARATIONS FOR WORK:
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from fall- ing. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to pro- vide safe footing.
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carry- ing out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. Always remove the lead from the nega- tive (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to pre- vent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
G.B 25/12/24
